Rotor blade structure

ABSTRACT

A system of spars, each having a rectangular cross-section, is provided by placing the spars in lateral juxtaposition to one another like a plank to form a rotor blade. A skin of plastic foam is provided on the blade. The cross-sections of the spars, and the corresponding cross-sections of the blade, are varied in accordance with aerodynamic requirements. The spars are kept in position by means of clamps and/or connections and/or rings, forming an integral unit similar to a plank; and the integrated spars are directly attached to a hub or an electric generator.

BACKGROUND OF THE INVENTION

The structure of rotor blades of wind operated power generators normally comprises a central aluminum spar, supporting nonstructural ribs and skin and joined by a steel tube to a hub, the tube being used as shank of the blade. A disadvantage of this construction results from the relative weakness of the spar near the hub, with high bending forces and load especially in a vertical plane during each full rotation of a wind wheel with horizontal axle.

SUMMARY OF THE INVENTION

It is therefore the idea of the invention to combine a number of spars in form of one integral spar unit and to cover it with integral plastic foam which also forms the skin, and is normally in the shape of an aerodynamic profile. The integral unit of spars is attached to the hub directly or by means of a clamp or connection forming a shank of the blade.

The different spars are glued together or welded and/or put together with outside clamps or rings, the unit having the appearance of a rectangular plank. It is possible to integrate a bigger number of spars near the hub, where the bending forces are stronger, and to diminish the number of spars over the blade's length, having the smallest number of spars at the tip of the blade. The structural strength of the integrated spars can be adapted in this way to the structural necessities of the blade.

The rectangular plank of the integrated unit of spars accords to the need of giving the blade an aerodynamical shape; that is, the dimension of each separate spar can be chosen in such a way that the totality of the spars follows the design of the aerodynamic profile. This structural method allows for the construction of relative small as well as relative long rotor blades; that is, the thickness of the spars varies according to the different thickness of the aerodynamic profile.

The foam for forming the external skin is directly laid on the unit of the profiles and/or is glued to the profiles. This can be done, in industrial practice, by means of a mold, with the use of injection techniques. If a twist is required, the different spars are arranged like a fan which is slightly opened, i.e. each spar is increasingly displaced in regard to the spar beneath of it, over the length of the blade, in such a way that the integral structure of the spars, in form of a plank, follows the direction of the twist which is required.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description with reference to the appended drawings, which are given by way of example, shows the manner by which the invention may be carried into effect.

FIG. 1 is a schematic perspective view of an embodiment of this invention, showing its completed outline only by broken lines, and broken off in the back portion; the view being taken approximately along lines 1--1 in FIG. 4;

FIG. 2 is a generally similar, partial view of the complete embodiment;

FIG. 3 is a plan view, showing a modified embodiment; and

FIG. 4 is a sideview showing one of the embodiments installed in a wind-driven generator unit.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 4, rotor blade structure 4' forms part of a wind wheel, turned by wind which impinges on it in direction 5'. The wheel is mounted, by axle 6', on a support 8' (preferably swingable about a horizontal pivot 7') which in turn is mounted on a vertical axis 2' on tower 1'. (Preferably, there is added a weight unit 9', 10', 11', 12' and, in many cases, a vane 3'; these parts are not important for the present invention).

As shown in FIG. 1, the blade structure comprises spars 1 to 12, which are put alongside in surface contact to each other, to form an integral structure similar to a plank. The position of a lower surface of spar 1 in regard to one of spar 2, and similarly in spar 2 in regard to spar 3, etc., is progressively displaced for following the twist angle of the profile 14 in one end portion of the blade structure. This angle, also shown by lines A, B, and this profile are not necessarily uniform along the blade; they can be different in another end portion 13, when compared with profile 14, in accordance with aerodynamic requirements of fan rotor blades, known to persons skilled in the art.

The spars 1-12 are glued or welded together and/or clamps 15a (FIG. 2) are attached for forming reinforcements 16 and 17 (FIG. 3).

A terminal clamp or connection or ring 15, welded or glued to the spars is attached to a hub, this clamp 15 forming the shank of the blade. In this way connection is made to the electric generator's hub 20 and which is mounted for example on support 8', FIG. 4. The clamp or connection can, if preferred, be fixed to the unit of spars with bolts (not shown) which are attached through holes 18 in clamp 15a (FIG. 2).

In many cases it is desirable that the number of spars is diminished at points 16 and 17 disposed at different distances from the ends of the spars, in accordance with structural necessities and in order to save material and weight. As shown in FIG. 3, three spars at the left side of the unit (seen from the right end of blade 19) extend only from the hub end of the blade connected with hub 20 to point 16, and three more on that side extend only to point 17, while other spars, at the opposite side, are similarly shortened.

Desirably, the number of spars is reduced, over the length of the blade, in such a way that the biggest number of spars is situated near the hub, where the greatest strength of the blade is required, and that the smallest number of spars is laid at the tip of the blade. This reduction of the number of spars may have the ratio of 100 near the hub; of 60 near the end of the first third of the rotor length; of 30 near the end of the second third of the rotor length; and of 10 at the tip of the blade.

It will be understood that the reduction of spars may have other ratios according to constructional necessities. It is also possible, to diminish the number of spars in ways different from that shown. For example, this can be done by stopping every third one, at 16, and every third remaining thereafter, at 17.

As already noted, a central aluminum spar has been used heretofore. The new spars 1 to 12 can also be made of aluminum. They are straight and each has a longitudinally uniform quadratic or other rectangular cross-section corresponding in its area to that of a directly embedding portion of the blade, as shown; they can also be either solid, as shown, or hollowed out into tubular forms. A skin or cover 21 of plastic foam, as shown, embeds the spars. It can be glued upon and integrated with the spars, and it forms an aerodynamic profile 13, 14. The rotor blade 19 forms an integral unit and is attached directly and/or with a clamp to the hub 20. A synthetic plastic foam cover is desirably made of polyurethane. The outside skin of this material is completely even, while the inside structure has very small holles, fitted with a mixture of air and gas and thus having a foam structure. It is therefore possible to form this structure by means of a mold. The aluminum and steel structure is put into this mold and the plastic is injected, forming the aerodynamic structure in the manner explained above. The advantage of this constructional method is given by the fact, that one rotor blade can easily be completed and a chain can be introduced for industrial, low cost production. The inside foam structure assures a minimum of weight (density 0.4-0.6) and cost. No further coating or polishing will be needed. 

I claim:
 1. A rotor blade for a wind generator, comprising;a plurality of straight spars each having a longitudinally uniform, rectangular cross-section, and all secured to one another in lateral contact with one another to provide an integral unit thereof, similar to a plank; a skin of synthetic plastic foam embedding the unit of spars and defining a rotor blade having an exterior, aerodynamic profile, the number of the spars, transverse of the rotor blade, diminishing longitudinally from a hub end of the rotor blade, and the uniform cross-section of each spar having an area corresponding to the cross-sectional area of a directly embedding portion of the rotor blade; and means for attaching the hub end of the rotor blade to a hub, whereby the rotor blade has maximum strength near the hub.
 2. A rotor blade according to claim 1 in which the spars are glued to one another for their securing to one another.
 3. A rotor blade according to claim 1 in which the spars are of aluminum and are welded to one another for their securing to one another. 